Transparent panel and surrounding closure and a method for its creation

ABSTRACT

A method of making a seal on a panel for a door or window by applying and curing a sealant on the surface of the panel is provided, preferably by screening the sealant onto the surface of the panel. The panel with the seal is mounted in a window or door frame such that the seal is disposed between the panel and the frame itself. To assemble the door or window, the panel may be inserted into “U” shaped grooves in the structural members comprising the door and the frame members assembled about the panel. The panel may have multiple layers with such seals interposed between the layers.

FIELD OF THE INVENTION

The present invention relates generally to the sealing oflight-transmissive planar panels to window or door frames. Moreparticularly, the invention relates to an improved technique forapplying a seal to a window pane and subsequently sealing the pane to awindow or door frame.

BACKGROUND OF THE INVENTION

Effectively sealing light-transmissive panels in window and door framesis a recurring problem for manufacturers. This problem is compoundedwhen the door or window frame to which the panel is sealed is an unevenor rough material, such as wood, or is exposed to wide variations intemperature. Previous sealing solutions include the application of aputty-like glazing compound between the panel and the frame to which thepanel is to be sealed. This method requires the manual application ofthe glazing compound to the surface of the door or window at theappropriate places, placement of the panel in contact with these sealingsurfaces, disposing panel retainers (commonly called “sticks”) againstthe panel to compress the glazing compound between the panel and thesealing surfaces, and attaching the sticks to the door or window frame(typically by nailing) to retain the panel within the door or window.During this process, the putty-like glazing may be extruded from betweenthe sealing surfaces and the panel, providing a bead of glazing thatmust be tediously trimmed once it has hardened.

There are several disadvantages to this process. First, the glazingcompound is often applied unevenly to the door or window frame beforeinsertion of the panel, thus providing a sealing layer of uneventhickness between the panel and the door or window. Even if it isapplied evenly, it may become uneven when the panel is pressed into theglazing on the frame and the glaze is thereby unevenly extruded, leavingvoids and gaps between the panel and the frame that often leak. Second,the extruded glazing compound is esthetically unpleasant, and must becleaned off, typically after it has hardened. Third, it is difficult tocompletely clean the extruded glazing compound off the panel and thedoor or window. Fourth, attaching each of the panel retainers takes aconsiderable amount of time and care.

There is a need, therefore, for an improved seal or gasket for atransparent panel and a method for installing that panel.

SUMMARY OF THE PRESENT INVENTION

The present invention provides a novel seal for, and method of creatingit on, a panel for a window or door. The seal is particularlywell-suited to sealing transparent panels, especially glass panels, inwooden doors or windows. A 0.005 inch to 0.5 inch thick seal or gasketmaterial is applied to the panel through a stencil or screen oriented inproximity to the panel. The sealant can be applied in a complex patternon the surface of the panel without time consuming efforts to manuallytrace out and apply the sealant on the surface. The sealant, typicallyhaving a liquid, gel or pastelike consistency, is then cured to a solidresilient state to form a gasket or seal. Once cured, the panel withbonded seal can be mounted in an opening in a door or window. The panelwith seal may be inserted into a preassembled frame and secured withpanel retainers, or may be compression assembled together with theindividual frame members.

Thus, in accordance with the present invention, a method for creating aseal for a panel is provided, including the steps of placing a screenhaving sealant transmissive regions in close proximity to the panel,conveying a sealant through the regions of the screen onto thelight-transmissive panel, and curing the sealant to form a resilientseal. The sealant may be plastisol and may be cured by heating. It mayhave a width of between 0.125 inches and 0.75 inches, and a thickness ofbetween 0.010 and 0.25 inches. It may be recessed from the edge of thepanel, preferably between 0.02 and 0.375 inches, and may have a hardnessof between 10 and 60 durometer, or more preferably between 25 and 40durometer.

In accordance with a second embodiment, a gas and liquid resistantclosure for a building is provided, having a structural frame, alight-transmitting panel having an outer edge mounted within thestructural frame, and a resilient seal disposed between the frame andthe panel, formed by applying a liquid sealant to a first surface of thepanel and curing the sealant. The panel may be glass or plastic, and maybe inserted in a door or window frame. The frame may have a groove forreceiving the panel and a portion of the resilient seal, such that theresilient seal is disposed between the panel and the frame. This groovemay have an included angle of less than twenty degrees, or morepreferably be between four and ten degrees. The frame may be formed ofwood.

In accordance with a third embodiment of the invention, a method forassembling a closure for a building having a transparent panel and atleast one structural member for supporting the panel is claimed,comprising the steps of applying a sealant to the edge of a transparentpanel, curing the sealant to form a resilient seal, and inserting afirst edge of the transparent panel into a groove in a structural memberin a direction substantially parallel to the plane of the panel andperpendicular to the first edge. The panel may be inserted so that theseal is disposed between the panel and a portion of the groove. A secondedge of the panel may be inserted into a second grooved structuralmember in a direction parallel to the plane of the panel andperpendicular to the second edge. The sealant may be applied in athickness of between 0.01 and 0.25 inches, and may be applied on one orboth planar surfaces of the panel.

In accordance with a fourth embodiment of the invention, a method ofcreating a window from a plurality of light-transmissive panels ofsubstantially the same planar dimensions is provided, including thesteps of applying sealant onto a first planar surface of a first panelalong its periphery, curing the sealant to form a first resilient seal,and joining a first planar surface of a second panel to the resilientseal. The sealant may be screened onto the first panel. Sealant may alsobe applied to the periphery of the second surface of the first panel andcured to form a second resilient seal. Sealant may also be applied tothe periphery of the second planar surface of the second panel and curedto form a third resilient seal.

Other principal features and advantages of the invention will becomeapparent to those skilled in the art upon review of the followingdrawings, the detailed description and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustration of a transparent panel and screen for applyingsealant thereto in close proximity;

FIG. 2 is a front view of a door constructed using the panel of FIG. 1;

FIG. 3 is a cross-section of the door of FIG. 2, showing one panel;

FIG. 4 is a cross-section of a door similar to that of FIG. 3, showing adouble glazed panel with interposed seal;

FIG. 5 is a cross-section of a door similar to that of FIG. 3 usingstructural members with grooves to retain the panel; and

FIG. 6 is an exploded view of a door comprised of the structural membersand panels of FIG. 5.

Before explaining at least one embodiment of the invention in detail itis to be understood that the invention is not limited in its applicationto the details of construction and the arrangement of the components setforth in the following description or illustrated in the drawings. Theinvention is capable of other embodiments or being practiced or carriedout in various ways. Also, it is to be understood that the phraseologyand terminology employed herein is for the purpose of description andshould not be regarded as limiting.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Turning now to the drawings, FIG. 1 illustrates the application ofsealant to a transparent panel 102 through a screen. The screen includesa frame 104 that holds the screen 106 in close proximity to panel 102,when frame 104 is lowered toward panel 102. Sealant 110, shown on thesurface of screen 106 is spread across the surface of screen 106 andpenetrates screen 106 through pattern 108 (a transmissive region ofscreen 106) which is adapted to transmit sealant 110 through screen 106to panel 102 when screen 106 is lowered into contact with panel 102.

The screen is preferably made of threads or ribbons of silk, metal,polymeric material or equivalents thereof. The screen preferably has amesh of between 10 and 90. More preferably, it has a mesh of between 30and 70. Most preferably, it has a mesh of between 40 and 60. Screenswith a larger mesh can be used with more viscous sealants, and willprovide a thicker layer of sealant than a finer mesh screen. A stencilmay be employed in place of screen 106.

Not all portions of the screen transmit the sealant. To prevent thetransmission of sealant onto the surface of the panel where it is notdesired, a sealant-proof film is typically applied to the surface of thescreen. The thickness of the applied film, and thus the thickness of theresultant sealant on the surface of the panel may be controlled byapplying multiple and successive layers of film to the surface of thescreen until the proper film thickness is produced. In this manner, thethickness of the sealant applied to the surface of the panel can becontrolled. The portions of the screen that have not been covered withfilm will transmit the sealant to the surface of the panel, such aspattern 108 of FIG. 1.

The screen shown in FIG. 1 is large enough to coat a single panel withsealant at a time. To provide for quicker production, the frame andscreen may be enlarged to permit a plurality of panels to be orientedbeneath a screen and simultaneously coated with sealant.

In FIG. 1, panel 102 is shown as having already been screened withsealant to create an uncured seal 112. The outer edge 114 of seal 112 isspaced away from outer edge 116 of the panel. This spacing is preferablyin the range of 0.02 to 0.375 inches. The width of the seal, measuredfrom its outer edge 114 to its inner edge 118 is preferably between0.125 and 0.75 inches. The thickness of seal 112 is preferably between0.01 and 0.25 inches, depending upon the type of panel (glass, plasticor wood) and the structural member to which the panel will be sealed.For most applications, such as those involving standard window glass asa panel material, a thickness of between 0.02 and 0.06 is preferred. Theseal, depending upon the ultimate application, can be created from asingle application of sealant, or can be built up by applying a sealantlayer, curing it, and then repeating the process until a seal ofsufficient thickness has been created. For seals on float glass panels,the sealant is preferably applied to the “air” side of the glass.

A seal can be applied to both sides of the panel to provide bettersealing and to allow the panel to “float” with respect to a structuralmember to which it is sealed, shown below in FIGS. 3, 4 and 5.Alternatively and preferably, it can be applied to a single side of thepanel.

A variety of sealants will provide a flexible resilient seal when cured.Plastisol, however, is preferred. Typically, the plastisol is applied tothe surface of the panel (glass, in the preferred embodiment) in themanner shown in FIG. 1 and the panel is then heat-cured in an oven.Glass-bonding additives are preferably added to the plastisol to improveits adhesion to glass. The viscosity of the plastisol sealant applied tothe panel is preferably in the range of 1-1.5 million centipoids,depending upon the environment. With a viscosity in this range, thesealant resists dripping or running once it is applied to the panel, yetis easily applied and curable to an acceptable hardness.

Heat-curing also varies depending upon the environment. For temperedwindow glass with a seal on the order of 0.03 inches thick, curing isperformed at 350 degrees Fahrenheit for five minutes, or 400 degreesFahrenheit for four minutes. As the curing temperature is increased, thecuring time may be reduced and vice versa. The curing is preferablyperformed in a conveyor oven, in which the glass with sealant applied tothe surface, is placed on a conveyor at the entrance of the oven, and isautomatically conveyed through the oven to the exit after the properamount of curing. The seal is preferably cured to a hardness of between10 and 60 durometer, and more preferably of between 25 and 40 durometer.With a hardness in this range, the panel can be easily mounted into awindow or door, yet will also provide an effective vapor or liquid seal.

FIG. 2 illustrates a typical door or window frame in which the panelwith seal is placed. In this embodiment, the door includes fourtransparent panels 202, 204, 206 and 208 with seals. The panels areseparated by a horizontal member 210, called a “bar” and two verticalmembers 212 and 214, called “muntins” or “mutts.” This panel assembly isoriented between two vertical members 216 and 218 called “stiles” andupper and lower members 220 and 222 called “rails.” In a typicalassembly, the bars, mutts, rails and stiles are assembled without thepanels to create the structural frame of the door or window. Onceassembled, the panels are inserted into the openings created in the dooror window frame (in a direction substantially perpendicular to the planeof the panel) and are retained within the frame by panel retainers or“sticks” (shown in FIG. 3) which are pressed against the free surface ofthe panel and attached to the frame, thereby preventing the panels frombeing removed. In the prior art, the openings in the frame were coatedwith glazing and transparent panels were inserted into the openings andsecured with sticks, causing the glazing extrusion, leakage, and cleanupdescribed above. By utilizing transparent panels with bonded seals,these problems are avoided, as shown in FIG. 3, below.

FIG. 3 shows a cross section (Section A—A in FIG. 2) of one of thepanels of the FIG. 2 door created as described above. The door containsa panel 204 with seals (indicated by items 302, 304, 306 and 308) formedaround the periphery of the panel similar to the seal shown in FIG. 1.Panel 204 is supported in the frame by frame elements 210, 214, 218 and220 (FIG. 2). Of these, frame elements 220 and 214 are shown in FIG. 3in cross-section. In this embodiment, the seals are disposed on bothsides of the panel to provide additional sealing capability. The panelis maintained in the frame by a panel retainer, which in this embodimentincludes four “sticks,” of which two (items 310 and 312) are shown incross-section. In this embodiment, the panel with seals is moved in adirection substantially perpendicular to the plane of the panel suchthat the seal is disposed between and is in contact with both the frameand the panel, as indicated by the arrow. Once the panel is insertedinto the frame, the sticks are placed against the second seal and arefastened to the door such that the second seal is disposed between panel204 and the sticks. By providing seals on both sides of the panel, thepanel can “float” with respect to the frame in which it is mounted.Alternatively and preferably, the seal can be removed from one side ofthe panel in the FIG. 3 embodiment, providing a single seal between thepanel and bonded to a single side of the panel.

While the seals of FIG. 3 are shown as a ribbon around the periphery ofthe panel, they need not be initially created in ribbon form. To createthe seals, a sealant can be applied to substantially all of the panel'ssurface, and then cured to provide a protective layer across the surfaceof the panel. This panel can then be mounted in an opening in a windowor door frame, as described above, and the excess sealant subsequentlytrimmed, leaving a portion of the seal disposed between the panel andthe structural member of the frame to provide sealing between the paneland the frame. In such an embodiment, the cured sealant provides notonly a seal between the structural members and the transparent panelduring use, but a protective layer on the exposed portion of thetransparent panel's surface during assembly and shipping.

Panels with seals are particularly suited to creating a multi-layerpanel for a door or window as shown in FIG. 4. In this embodiment, aplurality of panels 402 and 404, separated by a seal 406, have seals 408and 410 disposed on their outer surfaces. As in the prior embodiments,seal 406 is advantageously created by applying and curing a sealant onthe surface of panel 402. Once the seal is formed, this panel is thenjoined to a second panel 404 with the seal interposed between and incontact with both panels, to create a double glazed panel having agas-filled void disposed between them. As shown in this embodiment,additional seals 408 and 410, similarly created, may be provided onouter surfaces of this double glazed panel. This pair of panels can thenbe installed in a frame in the same manner that panel 204 of FIG. 3 wasinstalled.

This traditional method of construction is not necessary, however, whena panel with bonded seal, such as the one disclosed here, is employed.It is especially well-adapted to a new method of constructing a door orwindow that heretofore was impossible using the glazing and stickmethod. This new and preferred method of construction is disclosed inFIG. 5.

In the embodiment of FIGS. 2 and 3, the frame of the door or window waspreassembled and the panels were subsequently inserted in a directionsubstantially perpendicular to the longitudinal extent of the panel,followed by attachment of separate panel retainers. In the FIG. 5embodiment, however, the panel retainers have been eliminated since thedoor or window frame is assembled around the panel and seal, rather thanthe panel inserted into the frame after its assembly.

Panel 502 with seals 504 and 506 is maintained in a frame member 508 ina “U” shaped groove 510 having substantially parallel and opposinginterior surfaces 512 and 514. As with the panels of FIGS. 3 and 4, aseal can be applied to one or both surfaces of the panel. To provide foreasy assembly yet allow an effective seal, the walls of the “U” shapedgrooves preferably flare outward with respect to each other. This flare,shown here as angle φ, is preferably less that twenty degrees. Morepreferably it is between four and ten degrees. Mouth 516 of the groovepreferably has a minimum width equal to the combined thickness of panel502 and the uncompressed seal or seals 504 and 506 to be inserted in thegroove.

Unlike the embodiments of FIGS. 3 or 4, a frame having FIG. 5 groovesaround the entire periphery of a panel cannot be preassembled beforeinsertion of the panels. In such an embodiment the panel must beinserted into the “U” shaped grooves in a direction parallel to theplane of the panel (as shown by the arrow in FIG. 5), and therefore theframe must be assembled around the panel, rather than the panel insertedinto a preassembled frame. FIG. 6 shows an exploded view of a typicaldoor or window frame adapted to be assembled around panels. This frameis similar in overall construction to the embodiment of FIG. 2. Itdiffers in that the FIG. 6 embodiment has frame members with FIG. 5grooves (shown in FIG. 6 as dashed lines) that are adapted to beassembled around a panel, and not the panel retainers of FIG. 2.

To construct the FIG. 6 door, panels 602, 604, 606 and 608 with seals603, 605, 607 and 609 are compression assembled with mutts 610 and 612,bar 614, rails 616 and 618, and stiles 620, 622 and 606 to create a dooror window.

Panels with bonded flexible seals created by applying and curing asealant to the surface of a panel are especially well suited to such aconstruction technique, since the seal allows the panel to move relativeto the groove in which it is inserted, thus easing construction andreducing the risk of breaking a panel, and since the seal, by flexing,can allow some variation in the depth of panel insertion, while stillproviding a tight seal.

Wooden doors or windows show particular benefit in being constructed asdescribed above, especially outside doors that are exposed to theelements. The panel seal provides superior resistance to moisture andgas leakage. Since wooden door frame elements can rarely be manufacturedwith complete accuracy and are also prone to warping, the flexible sealadapts to such irregularities in the sealing surfaces during thecompression assembly process and to changes in such surfaces over timeas the individual frame members comprising the door or window begin toage. Furthermore, expansion and contraction due to wide temperaturechanges, such as those experienced by external doors and windows aremore readily accommodated by flexible seals.

Thus, it should be apparent that there has been provided in accordancewith the present invention a transparent panel and surrounding closureand a method for its creation that fully satisfies the objectives andadvantages set forth above. Although the invention has been described inconjunction with specific embodiments thereof, it is evident that manyalternatives, modifications and variations will be apparent to thoseskilled in the art. Accordingly, it is intended to embrace all suchalternatives, modifications and variations that fall within the spiritand broad scope of the appended claims.

The embodiments of the invention in which an exclusive property orprivilege is claimed are defined as follows:
 1. A gas and liquidresistant closure for a building, comprising: a structural frame; apanel having an outer edge mounted within the structural frame; a firstresilient seal which is cured on a first surface of the panel; and theframe defining a groove, the groove having a first wall and a secondwall that flare outward at an included angle of less than twentydegrees, wherein the panel and a portion of the first resilient seal arepositioned in the groove such that the first resilient seal is disposedbetween the panel and the first wall, and inner surfaces of the firstand second walls are spaced apart a distance sufficient to cause thepanel to be wedged into the groove without peeling the first resilientseal off the first surface when the panel is inserted into the groove,and further wherein the first resilient seal substantially cover all ofthe first surface of the panel.
 2. A gas and liquid resistant closurefor a building, comprising: a structural frame; a panel having an outeredge mounted within the structural frame; a first resilient seal whichis cured on a first surface of the panel; the frame defining a groove,the groove having a first wall and a second wall that flare outward atan included angle of less than twenty degrees wherein the panel and aportion of the first resilient seal are positioned in the groove suchthat the first resilient seal is disposed between the panel and thefirst wall, and inner surfaces of the first and second walls are spacedapart a distance sufficient to cause the panel to be wedged into thegroove without peeling the first resilient seal off the first surfacewhen the panel is inserted into the groove, further wherein a secondresilient seal is disposed on a second surface of the panel between thesecond wall and the second surface, and further wherein the first andsecond resilient seals substantially covers all of the first and secondsurfaces of the panel, respectively.
 3. The closure of claim 1, whereinthe panel transmits ambient light and is one of the group consisting ofglass and plastic.
 4. The closure of claim 1, wherein the structuralframe is one of the group consisting of a door frame and a window. 5.The closure of claim 4, wherein the included angle is between four andten degrees.
 6. The closure of claim 5, wherein the frame is comprisedof wood.
 7. The closure of claim 1, wherein the first resilient seal hasa cured hardness of between 10 and 60 durometer.
 8. A gas and liquidresistant closure for a building, comprising: a structural frame; apanel having an outer edge mounted within the structural frame; a firstresilient seal which is cured by heat on a first surface of the panel;and a groove located on the frame, the groove having a first and secondwall that flare outward at an included angle of less than twentydegrees, wherein the groove is designed to receive the panel and aportion of the first resilient seal such that the first resilient sealis disposed between the panel and the first wall, and inner surfaces ofthe first and second walls are spaced apart a distance sufficient tocause the panel to be wedged into the groove when the panel is insertedinto the groove without peeling the first resilient seal off the firstsurface.
 9. A gas and liquid resistant closure for a building,comprising: a structural frame; a panel having an outer edge mountedwithin the structural frame; a first resilient seal which is cured byheat on a first surface of the panel; and the frame defining a groove,the groove having a first wall and a second wall that flare outward atan included angle of less than twenty degrees, wherein the panel and aportion of the first resilient seal are positioned in the groove suchthat the first resilient seal is disposed between the panel and thefirst wall, and inner surfaces of the first and second walls are spacedapart a distance sufficient to cause the panel to be wedged into thegroove without peeling the first resilient seal off the first surfacewhen the panel is inserted into the groove, and further wherein thefirst resilient seal substantially covers all of the first surface ofthe panel.
 10. The closure of claim 9, wherein a second resilient sealis disposed on a second surface of the panel between the second wall andthe second surface.
 11. A gas and liquid resistant closure for abuilding, comprising: a structural frame; a panel having an outer edgemounted within the structural frame; a first resilient seal which iscured by heat on a first surface of the panel; the frame defining agroove, the groove having a first wall and a second wall that flareoutward at an included angle of less than twenty degrees wherein thepanel and a portion of the first resilient seal are positioned in thegroove such that the first resilient seal is disposed between the paneland the first wall, and inner surfaces of the first and second walls arespaced apart a distance sufficient to cause the panel to be wedged intothe groove without peeling the first resilient seal off the firstsurface when the panel is inserted into the groove, further wherein asecond resilient seal is disposed on a second surface of the panelbetween the second wall and the second surface, and further wherein thefirst and second resilient seals substantially cover all of the firstand second surfaces of the panel, respectively.
 12. The closure of claim9, wherein the first resilient seal has a cured hardness of between 10and 60 durometer.
 13. The closure of claim 9, wherein the frame isconstructed of wood.
 14. The closure of claim 9, wherein the paneltransmits ambient light and is one of the group consisting of glass andplastic.
 15. The closure of claim 14, wherein the included angle isbetween four and ten degrees.
 16. The closure of claim 14, wherein thestructural frame is one of the group consisting of a door frame and awindow frame.